1

SUMMER TRAINING REPORT AT NTPC, TANDA

Submitted To:
H.O.D.
Electrical & Electronics Engineeing Department

Submitted By:

ACKNOWLEDGEMENT
Upendra Kumar Singh

We hereby take this opportunity to thanks NTPC Tanda for giving us this opportunity to conduct our training in NTPC Tanda. We are grateful to Mr.B.P.Dubey (DGM-EMD) for allowing us to conduct our training in Electrical maintenance department .We are heartily indebted to our project guide Mr. S.C.Dwivedi, Supdt.(EMD) for providing us with detailed in depth knowledge and very useful information about the process and system used in the plant. His support was instrumental in our training being fruitful. We are also thankful to the entire officer and staff of NTPC Tanda for extending a helping hand whenever we need it.

Upendra Kumar Singh

Upendra Kumar Singh

ACKNOWLEDGEMENT
We hereby take this opportunity to thanks NTPC Tanda for giving us this opportunity to conduct our training in NTPC Tanda. We are grateful to Mr. A K SINGH (DGM-OPN) for allowing us to conduct our training in OPERATION department .We are heartily indebted to our project guide Mr.R K YADAV, Sr.Supdt.(OPN) for providing us with detailed in depth knowledge and very useful information about the process and system used in the plant. His support was instrumental in our training being fruitful. We are also thankful to the entire officer and staff of NTPC Tanda for extending a helping hand whenever we need it.

(Upendra Kumar Singh)

Upendra Kumar Singh

CONTENTS

S.No.

Description
Brief description of Tanda thermal project Production of electricity Basic power plant cycle Description of thermal plant Different cycles of a power plant Important equipment of plant Control and instrumentation unit Future prospects of NTPC Tanda

Page No.

1 2 3 4 5 6 7 8

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BRIEF DESCRIPTION OF TANDA THERMAL PROJECT

Geographical location:The Tanda Thermal Power Project is located about 185kms from Lucknow. It is nearly 55kms from Faizabad. The nearest rail ahead is Akhbarpur (now called as Ambedkarnagar). The project lies in the Ambedkarnagar district and is about 22kms from the nearest railway station. The complete project is situated on the bank of Saryu River. The climate conditions are quite favourable with greenery all around.

Features:The plant has been designed by M/s. Desein The installed capacity is 4 X 110 MW

The water requirement of the station is met from the Saryu River through Mehripur pumping Station constructed for feeding Mehripur Pump Canal. The coal linkages for the station have been provided from North Karnpura & BCCL. The power generation is evacuated through 220kV feeders connected to Sultanpur (2 feeders), Basti & Gorakhpur (1 each) 220kV substations. The total area of the power house including colony is 235 hectares and the land for ash disposal is 170 hectares. The main plant equipments like boiler, turbine and generator have been supplied by M/s BHEL Generator-transformer has been supplied M/s NGEF CHP(Coal Handling Plant) has been supplied by M/s TRF Cooling Towers by Paharapur Cooling Towers

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C&I(Control & Instrumentation sets) have been supplied by M/s ILK DM(De-mineralized) plant has been set up by M/s. WATCO, Hyderabad The designed boiler efficiency, turbine heat rate and unit heat rate are 84.7% and 2172.8kcal/kWh & 2565.3kcal/kWh respectively. The designed HHV of coal is 3850kcal/kg and the boiler is designed to work at worst quality of coal having HHV of 3400kcal/kg.

Tanda plant PLF:-

2000

2006

2008

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PRODUCTION OF ELECTRICITY
The means and steps involved in the production of electricity in a coal-fired power station are described below.

The coal, brought to the station by train or other means, travels from the coal handling plant by conveyer belt to the coal bunkers, from where it is fed to the pulverizing mills which grinds it as fine as face powder. The finely powdered coal mixed with pre-heated air is then blown into the boiler by fan called Primary Air Fan where it burns, more like a gas than as a solid in convectional domestic or industrial grate, with additional amount of air called secondary air supplied by Forced Draft Fan. As the coal has been grounded so finely the resultant ash is also a fine powder. Some of this ash

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binds together to form lumps which fall into the ash pits at the bottom of the furnace. The water quenched ash from the bottom of the furnace is conveyed to pits for subsequent disposal or sale. Most of ash, still in fine particles form is carried out of the boiler to the precipitators as dust, where it is trapped by electrodes charged with high voltage electricity. The dust is then conveyed by water to disposal areas or to bunkers for sale while the cleaned flue gases pass on through ID Fan to be discharged up the chimney. Meanwhile the heat released from the coal has been absorbed by the many kilometres of tubing which line the boiler walls. Inside the tubes is the boiler feed water which is transformed by the heat into the steam at high pressure and temperature. The steam super-heated in further tubes (Super Heater) passes to the turbine where it is discharged through the nozzles on the turbine blades. Just the energy of the wind turns the sail of the wind-mill, so the energy of the steam, striking the blades, makes the turbine rotate. Coupled to the end of the turbine is the rotor of the generator a large cylindrical magnet, so that when the turbine rotates the rotor turns with it. The rotor is housed inside the stator having heavy coils of copper bars in which electricity is produced through the movement of the magnetic field created by the rotor. The electricity passes from the stator winding to the step-up transformer which increases its voltage so that it can be transmitted efficiently over the power lines of the grid. The steam which has given up its heat energy is changed back into water in the condenser so that it is ready for re-use. The condenser contains many kilometres of tubing through which the colder is constantly pumped. The steam passing around the tubes looses the heat and is rapidly changed back to water. But the two lots of water (i.e. boiler feed water & cooling water) must NEVER MIX. The cooling water is drawn from the river, but the boiler feed water must be absolutely pure, far purer than the water we drink, if it is not to damage the boiler tubes. Chemistry at the power station is largely the chemistry of water.

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To condense the large quantities of steam, huge and continuous volume of cooling water is essential. In most of the power stations the same water is to be used over and over again. So the heat which the water extracts from the steam in the condenser is removed by pumping the water out to the cooling towers. The cooling towers are simply concrete shells acting as huge chimneys creating a draught (natural/mechanically assisted by fans) of air. The water is sprayed out at the top of towers and as it falls into the pond beneath it is cooled by the upward draught of air. The cold water in the pond is then circulated by pumps to the condensers. Inevitably, however, some of the water is drawn upwards as vapours by the draught and it is this which forms the familiar white clouds which emerge from the towers seen sometimes. Why bother to change stem from the turbine back into water if it has to be heated up again immediately? The answer lies in he law of physics which states that the boiling point of water is related to pressure. The lower the pressure, the lower the temperature at which water boils. The turbine designer want as low boiling point of water as possible because he can only utilize the energy of the steam when the steam changes back into water he can get NO more work out of it. So a condenser is built, which by rapidly changing the steam back into water creates a vacuum. This vacuum results in a much lower boiling point which, in turns, means he can continue getting work out of the stem well below 100 degree Celsius at which it would change into water.

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The above figure shows the ranking cycle graph which is used in a power plant. The paths shown below the figure represents the complete the whole steam and heat cycle as followed in different operation cycles of a power plant. BOILER: 4 no of radiant dry bottom natural circulation, vertical water tube boiler with single reheat 380ton/hr of steam pressure 160kg per square cm at 540 degree centigrade of temperature. TURBINE AND TURBO GENERATOR: 4 no. of 110 MW each. WATER TREATMENT PLANT:4x30 ton/hr capacity. OUTER SUBSTATION: a) Power Transformer: 4 no. of 125 MVA 11/220 kVA. b) Reverse Transformer: 2 no. of 30/20/10 MVA 220/66/33 kVA. RATED PARAMETERS: Rated parameter related to output: 110 MW. Economical Output: 95 MW. Rated Speed: 3000 rpm. Rated temp. of steam before steam valve: 540*C. Max. temperature of steam before stop valve: 543*C. Rated temperature of steam before MP casing: 540*C. Max. temperature of steam before MP casing: 543*C. Rated pressure of steam just before stop valve:130 atm. Max. pressure of steam just before stop valve: 136 atm. Normal pressure of steam before MP casing: 31 atm. Max. pressure of steam just before stop valve: 37 atm. Cooling water temperature: 32*C. SYSTEM OF THE TURBINE:
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2 Stop valve, one on either side of HP casing. 4 Control valves, 2 on either side of HP casing. 2 Stop valves, one on either side of MP casing. 2 Interceptor valves, one on either side of MP casing. 2 Row circuit wheels, 8 moving wheel in HP cylinder. 8 Non regulated extraction and one reheat. Weight of HP rotor (approx.): 5,500 kg. Weight of MP rotor (approx.): 11,000 kg. Weight of LP rotor (approx.):24,000 kg. Direction of rotation: Clockwise looking at the turbine from the pedestal 1. Barring speed: 62 rpm. DETAILS OF TANDA 110 MW # TG is designed by M/S SKODA supplied and manufactured by BHEL. # TG are supported by 7 journal bearings & coupled by 3 rigid couplings. Bearing no. 2 is thrust cum journal bearing. # HP TURBINE: Two concentric casing horizontally split up. Double Row single circuit wheel and 8 impulse stage wheels. # MP TURBINE: Two concentric casing horizontally split up, 12 stage out of which integrate forged with shaft & 4 shrunk fitted. # LP TURBINE: 2X4 reaction stages when steam flow is diabolize. All 8 wheels are shrunk fitted. # LP HEATERS: 1, 1A, 2, 2A are vertically mounted on LP casing. #EXTRACTION: 8 uncontrolled extractions, 3 from LP turbine, 4 from MP turbine and 1 from HP outlet.

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DESCRIPTION OF THERMAL PLANT

The plant is in fact designed on the modern concept of unit system. Each of the turbo-generator is connected to its individual steam generating plant. The steam turbine has inlet steam pressure of about 130kg/cm2 and super heat type with a reheat temperature of 540 0C. Regenerative feed heating with 8 stages heaters have been adopted. There are two high pressure feed water heaters connected with the exhaust of the H.P cylinder and the second one from an extraction of I.P cylinder. Constant pressure de-aeration is adopted for de-aeration and is fed from auxiliary system header of the plant which maintains the de-aeration pressure of 6kg/cm2 under all load conditions. There are five low pressure heaters two connected to the IP (Intermediate Pressure) heaters. The heat input from the grand steam condenser and the ejector condenser is also recovered to improve the cycle efficiency. Drip pump is also used to pump the drain from the 3rd LP (Low Pressure) heater back to the condensate system. This also adds to the efficiency of the system. Drains from various stages of steam turbine are treated so that the maximum thermodynamics benefit is derived. The plant is also provided with automatic control features. The operation of the Coal Handling, Ash Handling, Water treatment Plant, River water Intake pump is provided with remote as well as local manual control features to cope with the requirements of such large units.

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DIFFERENT CYCLES OF A POWER PLANT

For proper functioning of a power plant, its working operation has been divided into following main operation cycles. Steam cycle Feed water cycle Condensate water cycle Primary air cycle Flue gas cycle Secondary air cycle

Steam cycle: - This cycle basically deals with the flow of steam at
different pressure and temperature to different turbines namely HP, MP and LP turbines which are connected to the generator. It can be explained from the figure shown below

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Steam coming out from super heater at 540degree C and 139kg per square cm. Three cylinders of 2 set of main stop and governing valve arrangement on either side of HP casing and each set consist of one stop valve and 2 governing valve assembling series. The steam from the boiler is admitted the reheater where it heated at original temp. The reheated steam is taken to IP casing through combined stop and interceptor valve arrangement at either of IP casing. The exhaust from the IP casing has taken directly the LP casing. The steam expanded in the LP turbine to a very low blade pressure which is maintained by the condenser below atmospheric pressure about 3% of makeup water is required to condensate the losses of cooling water due to evaporation in cooling tower. Finally steam exhausted by LP turbine is condensed in the surface type condenser type cooling water following through a large no. of tubes. The HP, IP &LP turbine coupled in series and mechanical power generated from steam transmitted to generator.

Feed water cycle: - this cycle deals with the flow of water to boiler feed
pump from feed storage tank, which is later fed to the boiler drum passing through high pressure heater and economizer

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This system plays an important role in the supply of feed water to the boiler at requisite pressure and steam/water ratio. This system starts from boiler feed pump to feed regulating station via HP heaters Boiler feed pump: this pump is horizontal and barrel design driven by an electric motor through a hydraulic coupling. All the bearings of the pump and motor are forced lubricated by oil lubricating system. The feed pump consists of pump barrel into which is mounted the inside starter, together with rotor. Water cooling and oil lubricating are provided with their accessories. The brackets of the radial bearing of the suction side and the radial and thrust bearing of the discharged side are fixed to low pressure. High pressure heater: these are regenerative feed water heater operating at high pressure and located by the side of turbine. It is connected in series on feed water side and by such arrangement the feed water after feed pump enters the hp heater. the steam supply to these heater from the bleed point of the turbine through motor operated valves.

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Condensate water cycle: - It deals with the water flowing through the
condenser which plays an important role in increasing the efficiency of the plant. It consists of a feedback path from main ejector to hot well.

The steam after condensing in the condenser known as condensate, is extracted out of the condenser hot well by condensate pump and taken to the de-aerator through ejectors, gland steam cooler and series of LP heaters Condensate pump: the function of these pumps is to pump out the condensate to the deaerator taken to the de-aerator through ejectors, gland steam cooler and series of LP heaters. This pump is rated generally for 160 cubic meter/hour at a pressure of 13.2 kg/cm square.

LP heater: - there are four LP heaters in which 4 extractions are used.

These heaters are equipped with necessary safety valves in the steam space level indicator. The condensate flows in the u tube in 4 passes and extraction steam washes the outside tubes.

Deaerator: - the inner corrosion can be prevented by removing dissolved

gases from the feed water. it can be achieved by embodying into the boiler
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feed system a deaerating unit whose function is to remove the dissolved gases. it works on two principles:: Henry law and solubility law. Solubility law: solubility of gases decreases with increase in pressure and /or decrease in pressure. Henry law: the mass of gas with definite mass of liquid will dissolve at the given temperature and is directly proportional to the partial pressure of the gas in contact to liquid.

Primary air cycle: - In this cycle, air is used to carry pulverized coal
from mill to the burning zone of boiler. Two P.A fans in a thermal power plant to produce air of required quality( pressure around 700mm of water column) to elevate the powdered coal from the pulveriser to the burner. For supplying coal 2 each & every elevation one pulveriser is there & the temp. of mixture of coal and air is controlled by mixing hot(throughAir Pre Heater) and cold primary air at the inlet of pulveriser.

Secondary Air cycle: - In this cycle, fuel is mixed with air (known as
secondary air) for proper burning of coal .Secondary air is made available from forced draft fans. F.D fans take suction from the atmosphere and discharge through the wind box arranged to both left & right of the boiler .First wind box is at the corner 1&2 and the other at the corner 3&4.The required quantity of Secondary air into the furnace from the wind box is measured in terms of oxygen in the flue gas is controlled by a no. of secondary air dampers placed b/w wind box & furnace.(4 nos. for each elevation).

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Flue gas cycle: - In this cycle, gas containing waste materials are
removed from the system using various techniques like electrostatic precipitator, ID fans etc. The flue gas, before being removed is used to heat the primary and secondary air.

IMPORTANT EQUIPMENTS OF PLANT

I.

Mechanical Equipments:a.) Steam generating unit:-

Each steam is of semi outdoor, natural circulation, balanced draft type designed to burn coal in pulverized form. It is direct fired type meeting the requirements of latest Indian Boiler Regulation. It has a boiler rating of 375/380 tonnes per hour of steam at a super-heater outlet, at a steam condition of 139kg/cm2 and a temperature of 5400C. A re-heater is provided for reheating the exhaust steam from high pressure system of the turbine to 5400C. The boiler furnace and the gas passages are designed for low pressure in order to minimize the corrosion & slugging effect. Closed pitched bore wall tubes with membrane/skin type construction is adopted for the steam generator furnace walls to ensure maximum availability and efficiency at MCR not less than 86%. The unit is provided with two forced draft and two induced draft fans driven by constant speed electric motors. Each fan is rated for 60% of MCR rating. Regulation of draft system is by inlet vane control for Forced Draft fan. Shut off dampers is equipped with pulverized coal firing air fans, coal air pipes, burners, etc. Four five pulverized mills are provided for each steam
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generator out of which 3 4 are capable of meeting MCR with design coal. Flame scanner is also provided. Furnace Surface Safeguard Supervisor (FSSS) system is also provided to reduce the risk of explosions and back fires in the steam generators. For flame stabilization as well as operation at lower loads, oil burners are provided. Light oil/gas pilot torch system is adopted for ignition of furnace oil and pulverized coal.

b.) Mechanical
Precipitators:-

Dust

Collector

&

Electrostatic

Combined mechanical dust collector & electrostatic precipitator are provided to arrange arresting of fly ash in order to reduce particle. Efficiency of about 98% is achieved in this combined system.

c.) Turbine Generator Unit:A standard multi-stage, tandem compound extraction type, reheat type, condensing turbine with seven uncontrolled extractions, operating at 3000rpm is designed to operate with steam condition of 130kg/cm2 at 5350C at the throttle with reheating at an intermediate stage of 5350C and the exhaust against a condenser pressure of 0.092kg/cm2 absolute is provided and is directly coupled to a hydrogen cooled horizontal shaft, totally enclosed rotating field type generator, designed to generate at 11,000kV, 50Hz, 3-phase with suitable high frequency excitation system. The turbine and the generator have a nominal rating of 1, 10, 000kW and 1, 25,000kVA respectively at 2kg/cm2 H2 (gauge) pressure. The turbine is provided with hydraulic (oil) governing system. The turbogenerator is complete with all auxiliary systems and equipments, lubrication systems, shaft, gland seal system, motor operated turning gear. All necessary protective and supervisory instruments are provided to ensure trouble free,
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safe and efficient operations of the units. The turbine generator is manufactured by M/s. BHEL.

d.) Condensing Equipments:Turn surface condenser of identical design, capable of maintaining a vacuum of about 0.92kg/cm2 while condensing the steam at maximum rating of the turbine is provided. These tubes are of aluminiumbrass and tube sheet is of aluminium-bronze. The condensers are spring mounted and directly connected to the exhaust flange of the turbine with its axis to the right angles to that of the turbine. One starting ejector and two 100% capacity running ejectors are provided to create and maintain the vacuum in the condenser by taking out air and other non-condensable gases.

e.) De-aerating heater & Closed heaters:The unit is provided with a de-aerating heater and proper capacity of a feed water tank of approximately 14min storage capacity when machine is running at full load. The tray type de-aerator is designed to keep the oxygen content to 0.007ppm so that the oxygen content in the boiler feed pump water is kept below any chemical detection. Steam from extraction line and auxiliary heater is supplied to the de-aerator which maintains a constant pressure of 6kg/cm2 abs. and the boiler feed pump at the constant pressure irrespective on the load on the turbo-generator. The feed tank of de-aerator heater is placed on a suitable elevation to provide sufficient NPSH for the boiler pumps. Level controllers & communication through level switches is provided to keep the level of the condensate in the storage tank at a preset value. Regenerative in the storage on the condensate is carried out in seven stages by steam of non-regulated extraction from the turbine and tapping from cold reheat lines. The high pressure cold heaters are both drain cooling and de-

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superheating zones in addition to normal condensing zones. The low pressure feed water heaters are equipped with only drain cooling and condensing zones.

f.)

Boiler :-

A steam generator is complex integration of following accessories: 7. Div panels 8. Platen SH 9. Re-heater 10. Burners 11. APHs

1. Economizer 2. Boiler drums 3. Down comers 4. CCW pumps 5. Bottom ring header 6. Water walls

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Economizer:-

Boiler Economizer is feed-water heaters in which the heat from waste gases is recovered to raise the temperature of feed-water supplied to the boiler.

It preheats the feed water by utilizing the residual heat of the flue gas. It reduces the exhaust gas temperature and saves the fuel.

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It is an enclosed Pressure Vessel

Heat generated by Combustion of Fuel is transferred to water to become steam Serves two main functions. Separating heat from the mixture of water and steam.

It consists of all equipments used for purification of the steam after being separated from water.

Boiler drum level control:-

Important for both plant protection and equipment safety.

Maintain drum up to level at boiler start-up and maintain the level at constant steam load. Decrease in this level will uncover boiler tubes and get overheated and damaged. Increase in this level will make separation between steam and moisture difficult within drum. Controlled circulation is required to maintain the difference in the density between water and steam with increase in pressure.

Down comers: It carries water from boiler drum to the ring header.
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They are installed from outside the furnace to keep density difference for natural circulation of water & steam. Heating and evaporating the feed water supplied to the boiler from the economizer.

Water wall: These are membrane walls, no. of tubes are joined. Vertical tubes connected at the top and bottom of the Headers. Receives water from the boiler drum by down comers.

Advantage: Increase in efficiency Better load response simpler combustion control. Quicker starting and stopping Increased availability of boiler. Heat transfer is better Weight is saved in refractory and structure Erection is made easy and quick

g.) HP & LP Bypass System:Provision of HP & LP bypass system is proposed having a capacity of 40% steam bypass, making the unit suitable for quick restart as well as peaking
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purposes. This has been necessary on account of grid conditions which shows very acute storage of peaking.

II. Electrical Equipments:a.) Generator:The generator is directly coupled with its respective turbine normally rated for 110 MW at 0.88 power factor (i.e. 125 MVA), 11kV, 3 phases, 50Hz. The hydrogen cooling mechanism is used for the generator. The neutral point of the generator is earthed through a single phase Distribution Transformer, the secondary of which is shunted through a suitable resistance. The excitation system consists of high frequency AC mains and pilot exciters directly driven from the main shaft, silicon rectifying unit and associated control gears.
b.)

Generator Transformer:-

The generation voltage of 11kV is stepped up to 220kV by generatortransformer (in short GT) whose low voltages side is directly connected with the generator through an isolated phase bus duct. The rating of generatortransformer is 125MVA, 11/220kV, 3 phase, 50 Hz having an ON/OFF cooling. The high voltage side of the transformer is connected to the 220kV system in 220kV switchyard.

c.)

Unit Transformer:-

The bus-duct leading from the generator to the GT is tapped off conveniently for connection to high voltage side of Unit Auxiliary Transformer used for stepping down the voltage to 6.6kV for supplying power to the unit auxiliary loads of the power station. The rating of the UAT is 15MVA, 11/6.6kV, 3phase, 50 Hz.

d.) Start-up cum Reserve Transformer:-

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Each of the four units draw its start up power from the 220kV system through two/three windings common start-up cum reserve transformer rated for 30/10/20 MVA, 220/33/6.6 kV, 3 phase, 50Hz. The transformer supplies the 33kV load requirements. This transformer also meets the requirement of station loads like coal & ash handling, compressed air and water treatment plant, station lightening and other common services as well as act as a standby source of power to unit auxiliaries.

e.) L.T Auxiliary Transformer:For further step down of 6.6kV power from the reserve system for utilization at medium voltage 16 nos. 1000kVA, 6.6kV/415V, 3-phase, 50Hz transformers have been envisaged. The actual requirement is assessed after detail design of the system. Power for station illumination, unit wise is provided by five 300kVA, 6.6kV/415V, 3-phase, 4 wire transformers.

f.) DC Supply System:A station battery unit, complete with battery charger and control & distribution system is installed as required for supply to all loads either for normal operation or during any emergency conditions. Exact rating is however determined after the detail study of all loads and their durations.

g.) Switchgear:The drives for auxiliary equipment rated 150kW and above are operated at 6.6kV and drives having a rating below 150kW are operated at 415V, 3phase, and 4-wire system having a provision for single phase 230V. For starting up of these motors suitable switchgears/starters are provided.

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6.6 kV Switchgears 6.6 kV power received from either Unit Auxiliary Transformer or Reserve Transformer are connected to respectively 6.6kV switchgear bank through suitable breakers for further distribution to motors and to transformers for further step down to 415V. 2. 415 V Switchgear The 415V supply from each 1000kVA transformer are connected to a suitable 415V bus having its distribution for different motors and starters. Motors capacity above 90kW are controlled by a 415V breaker from respective bus and that of lower capacity by magnetic contractors grouped together in a sheet metal cubicle for a number of motors, termed MCC. Protection and control for individual motors is provided there.
1.

h.) 220kV Switch Yard:

Generator Transformer step-up the 11 kV voltage generated by the Generator to 220 kV. This voltage is used to charge the three buses in the Switch yard which follows Double Bus Bar with Transfer Bus Scheme. Switch yard provides protection between generator transformer and transmission lines. Major components of 220 kV Switch yard is: Buses (Bus #1, Bus #2 & Transfer Bus). Isolators. Circuit breaker.(Air Blast Circuit Breaker) Current Transformer (CT). Capacitor Voltage Transformer (CVT). Wave Trap. Potential Transformer (PT). Bays(4-Transmission line , 4-GT , 2-Station transformer , 1-Bus coupler , 1- Transfer Bus) The 4 Transmission lines are Basti Line, Gorakhpur Line, Sultanpur-I Line and Sultanpur-II Line.

III. Auxiliary systems:

The following auxiliary systems for the 4X110 MW as envisaged is described below:-

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Railway is only the means of transport of coal to this power station. Annual coal requirement for 4X110 MW units is estimated to be approximately 13.70 lakhs mega tonnes. The coal yard in the layout is adequate for about 30 days storage with two coal stock piles and considering 3800 MT of coal requirement daily. Considering inadequate & irregular coal movement by railways it is adequate to have a marshalling yard capable of handling two rakes a day normally & three rakes occasionally. Railway siding and marshalling yard is capable of meeting this requirement. The coal handling system consists of two wagon tipplers with integral weight bridge and marshalling equipment for unloading coal into hoppers. Duplicate belt conveyor system each rated 600 tons/hr feeds coal from the tippler hoppers to Crusher House. There are two crushers, each rated 600tons/hr. Crushed coal is either stacked in crusher coal yard or conveyed straight to power house. Duplicate conveyor system carries coal to the top of boiler bunkers. To stackers/re-claimers are there for stacking and re-claiming of coal each rated 600 tons/hr. In the power house, over the bunkers, duplicate belt conveyors run, each provided with a travelling tippler. Suitable arrangements are made for magnetic separation of iron particles from coal at the inlet to the crusher house. An automatic belt weighing system is provided at the power house entry point to register the amount of coal fed into the bunkers.

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For emergency, manual arrangements are made for unloading the coal from wagons and conveying the same to the crusher house. Necessary dust suppressing equipment and ventilation equipment is provided as a part of the coal conveying system. The operation of the entire system is controlled and supervised from control room. The system also has necessary interlock & safety features. For the purpose of shunting, it has three diesel locomotives.

b.) Fuel Oil System:The fuel oil is made available to the power station in tank wagon. The lighter grade oil such as light diesel oil is made available for starting of boiler from cold condition & furnace oil is made available for flame stabilisation purpose during low load operation and during any other period when flame stability is not satisfactory. The oil received from the tank wagon is pumped into the storage tank. The railway siding facilities provided is able to accommodate on the rake of tank wagons. Two storage tanks for heavy oil and one for light oil is provided. Provision is made for heating the tanks, steam tracing the piping and supply of heating steam to tank wagons. Oil from storage tank is pumped into day oil tanks. The day oil tank is located near the boiler. Pumps and heaters sets of suitable design then pump the oil from day storage to the burner. Return oil is fed back into the day tank. Similar installation is provided for the light oil but the day tank is not present.

c.) Ash Handling System:The ash disposal area is within the distance of 4~5kms from the power station and this is a low lying area. The ash from the boiler hoppers is conveyed to the ash disposal area either by direct sluicing or hydropneumatic system. Boilers manufactured by M/s. BHEL or AVB are so designed that it was possible to adopt either of the system for both fly as well as bottom ash.

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The ash disposal area has adequate capacity for storage of ash for a 640 MW station for over 15 yrs without reclamation. This area is now being used by Jaypee cement factory for production of cement and ash bricks. However this area may also be used for agriculture purposes by covering it with a layer of silt brought from the raw water reservoir in future.

d.) Cooling Water Management:The general arrangement & the system have been discussed earlier in the report. Only the equipments involved in the mechanical system are described below:Water from the raw water reservoir is pumped through clarifloculators. The clarified water from these clarifloqulator flows to the cooling water basin by gravity. A clarified pump is present which pumps the clarified water to the DM plant. For this, three pumps are involved. The outlets from the cooling water tower basins are connected to the common tunnel which takes the water back to the power house. From this tunnel water is drawn through the following pumps to the various equipments as follows:-

1.

) CW Pumps for circulating cooling water through turbine, condenser and discharging the same to the op of the respective cooling towers. Two CW Pumps each rated 50% capacity is installed. 2. ) Auxiliary Cooling Water Pumps for supplying cooling water to various auxiliary equipment for their cooling. This water after circulation through various bearings and heat exchangers leads to the CW discharge pipe from the condenser for cooling through the cooling tower. The number of pumps in this case is also two, each of 50% capacity.

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) Ash Water Pumps for supplying water for ash handling. There are two pumps per unit. Ash water is discharged to the ash disposal area but this continues the part of cooling water blow-down as well and therefore forms the part of total make-up water of the cooling tower. e.) Water Treatment Plant:A demineralising plant is provided for supplying make-up water for the heat cycle. Clarified water is pumped from the clarified water storage pit which passes through pressure filter, activated carbon filter, cation exchanger, degasifier, anion exchanger and mixed bed exchanger. There are four streams each rated 30m3/hr. Adequate facilities are provided for unloading, handling and storage of chemicals. Waste effluent is neutralised before it is discharged to outside drain.

3.

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CONTROL AND INTRUMENTATION UNIT

With the increasing size of modern plant, the distance between items of plants and centralised control room. Also, with large no of instruments, it becomes very difficult to watch many instruments and supervise the operation of such a large no of equipment. A control unit relives the operator from routine tasks, leaving him free to concentrate on the over all inspections. Also it is very difficulty the operation engineer to keep to keep constant watch on these temperature gradients, but its become very easy by using control units. The conventional central control unit is rather a cumbersome system. Large no of instruments must be observed to know what is happening in side the plant. The job is simplified by collecting all measurements transmitted from the process, converting them into digital form and printing them on to log sheets. All the important measurements at one time are printed along arrow. The major variables to be controlled are:Super heater & re-heater outlet temperature at a preset value Feed water flow to the steam generator Mill temperature Combustion control by controlling fuel air Condensate recirculation from condensate discharge line to the condenser Level control of heaters, condensers & clearator feed tan Boiler feed pump recirculation control Drum level

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DISTRIBUTED CONTROL SYSTEM

EXPLANATION It is a closed loop or feedback system. System is set to fixed value known as SET POINT. Deviation of the measured value from set value describes the controlling action to be performed. Control value to be sensed by sensor and the deviation from SET Pt. is measured and a Error signal is generated.

Types of controller used in a power plant

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LOCAL CONTROLLER

Outdated controllers Individual controller for each unit like turbine , boiler, generators etc Centralized data collection centre. Manual monitoring is done. Outdated technology.

DATA ACQUISITION SYSTEM CONTROLLER

DISTRIBUTED CONTROL SYSTEM

Recent technology topic to discuss in detail.

DDCMISTECHNOLOGICAL BACKGROUND
(Distributed Digital Control, Monitoring Information System)

PROGRESS OF INSTRUMENTATION USED TO IMPLEMENT AUTOMATIC PROCESS CONTROL

LOCAL PNEUMATIC CONTROLLERS MINIATURIZED AND CENTRALIZED PNEUMATIC CONTROLLERS AT CONTROL PANELS AND CONSOLES

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SOLID-STATE CONTROLLERS COMPUTERISED CONTROLS (SUPERVISORY) DIRECT DIGITAL CONTROL(DDC) DISTRIBUTED MICROPROCESSOR BASED CONTROL

Disadvantages of earlier Systems Analog instrument panels required huge space, lot of wiring and are less user friendly for monitoring of large number of parameters. Accuracy obtained with solid-state controls is not good and they tend to drift with time. Supervisory controls are inflexible as changing of control configuration requires change in routing of wires.

Use of centralized control leads to complete failure.

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MAN-MACHINE INTERFACE INFORMATION SYSTEM

AND

PLANT

64-BIT SERVER/OWS WITH HIGH-SPEED AND LARGE MEMORY (256/512 MB RAM, 8 GB HDD FOR SERVER AND 128/256 MB RAM AND 4/6 GB HDD FOR OWS) TO ENSURE FAST RESPONSE

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PROVISION OF LVS CONNECTION TO STATIONWIDE WAN OTHER SYSTEM THROUGH

TRANSPARENCY NO 9 & 10 MMIPIS FUNCTIONALITIES VPC OPERATION OTHER OPERATOR VARIOUS DISPLAYS INFORMATIONS THROUGH

ALARMS, LOGS, HISTORICAL AND LONG TERM STORAGE. PERFORMANCE AND OTHER CALCULATIONS

BRIEF INTRODUCTION OF maxDNA

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Bharat Heavy Electricals limited (BHEL), Electronics Division, has entered into a Technical Collaboration Agreement (TCA) for the manufacture and supply of new generation Distributed Control Systems 'MAX1000+PLUS' , for modern Power Plants & Industries, with MAX Control Systems (MCS) Inc USA, part of METSO Automation. The MAX1000+PLUS is now re-named as maxDNA. Where-in DNA stands for Dynamic Network of Applications. maxDNA is a network of applications where diverse hardware and software solutions co-operate to allow the plant to reach its greatest potential. BHEL's Electronics Division has established itself in the area of Control & Instrumentation for new power plants as well as renovation and modernization of existing power plants. A leader in the Indian Power Sector market, it has already supplied and commissioned above 200 sets of DCS for thermal, combined cycle and hydro sets all over the country and overseas. MCS Inc., USA, former systems division of Leeds and Northrop, USA, is an internationally reputed technology leader In both Power as well as Industrial process control systems, with 70 years of rich experience in the field. Applications maxDNA systems are used in many applications throughout the world including electric power generation, co-generation, cement, glass, ceramics, primary metals, chemicals and petroleum, water and waste-water treatment and incineration plants. BHEL offers a variety of solutions for Power Plants ranging from simple control systems to complex unified automation for Power Plants of any size. The synergy of BHEL's expertise in Power Plant Controls and cutting-edge technology of maxDNA provides for
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unified DCS solution for entire Power Plant comprising of Steam Generator, Steam Turbine Generator and Balance of Plant C&I. The state-of-the art control system is also configured for complete range of Hydro Turbine governing and auto sequence controls, SCADA systems and for wide range of industrial process applications. The spectrum of applications in brief are as listed. Power Plant Controls o Steam Generator Controls o Heat Recovery Steam Generator (HRSG) controls o Steam Turbine controls o Industrial Steam Turbine Controls o Balance of plant controls o Data Acquisition and information management o Hydro Turbine Governing and Auto sequence controls o Generator and Switchyard controls o Electrical System controls o Fossil power utility plants o Combined cycle power plants o Captive power plants

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UNIT DISPLAY OF maxDNA

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Furnace Safeguard Supervisory System(FSSS)

FSSS (Furnace Safeguard & Supervisory System) is used in almost all types of boilers to ensure safe operation. The system has been designed to offer maximum protection, minimum nuisance trips, minimum power consumption and maximum life of the components used. It is to ensure the execution of the safe, orderly operating sequence in the start-up and shutdown of fuel firing equipments in a boiler and to prevent errors which may be committed by an operator due to ignorance. The system is complex one and has got multiple steps which cannot be left at the discretion of operators to follow it in a sequential manner. The system is designed in such a manner that it eliminates the possibility of the unburnt fuel accumulated inside the furnace that may lead to explosion on sudden ignition. The BMS (Burner Management System) or FSSS system shall be designed to perform the following functions Prevent firing unless a satisfactory furnace condition obtained (furnace purge completed). Prohibit start-up of the equipment unless certain permissive interlocks have been completed. Monitor and control the correct component sequencing (manual or automatic) during start-up and shutdown of the equipment. Conditionally allow the continued operation of the equipment only while certain safety interlocks remaining satisfied. Provide component condition feedback to the operator and, if so equipped, to the plant control systems. Provide automatic supervision when the equipment is in service and provide means to cut out the fuel supply to the furnace in case of unacceptable firing conditions. Cut out fuel (MFT) upon certain adverse unit operating conditions.

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Turbine Supervisory Instrumentation(T.S.I)

Some important are measured for supervision of the turbine are as follows:1. 2. 3. 4. 5. 6. Turbine speed Shaft eccentricity Bearing vibrations Differential expansions Overall expansions Axial shift

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FUTURE PROSPECTS OF NTPC TANDA

NTPC Tanda is providing electricity to 3 different cities (Gorakhpur, Basti & Sultanpur).At present time, plant is delivering electricity up to PLF 102% i.e. generating power more than specified. In near future, generating capacity of plant is going to be increased by two units of 660MW each. So NTPC is playing a major role in development of INDIA.

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REGARDS:For the humble guidance and cooperation, we are thankful to Mr. B.P.Dubey (DGM-EMD) Mr. S.C.Dwivedi (Sr. Supdt.-EMD) Mr. Anil Srivastava (Asst. Engineer-EMD)

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